JP5916298B2 - Coil device - Google Patents

Description

  The present invention relates to a coil device provided with a sensor.

  Large-capacity coil devices (for example, reactors) used in hybrid vehicle and electric vehicle drive systems, etc., generate a large amount of heat due to iron loss and copper loss at high loads. The coil overheats and the characteristics deteriorate. For this reason, some large-capacity coil devices employ a configuration in which a temperature sensor (for example, a thermistor) is used to monitor the temperature in the coil device so that the coil device does not rise above a certain temperature.

  The reactor disclosed in Patent Document 1 has a pair of linear coils arranged in parallel to each other and connected at one end, and a temperature sensor is arranged between the linear coils.

JP 2010-203998 A

  In the sensor arrangement of Patent Document 1, high responsiveness can be obtained with respect to the temperature change of the coil, but since the temperature sensor is shielded from the core by the coil, the temperature change of the core cannot be detected quickly. It was.

A coil device according to an embodiment of the present invention is a coil device that includes a coil and a core that is at least partially passed through the coil, and further includes a sensor that detects a predetermined physical quantity in the coil device, This is a coil device in which a sensor head of a sensor is disposed between a core and a coil.
According to this configuration, it is possible to detect a change in the state of the coil (for example, a temperature change) more quickly. Further, since the space between the core and the sensor head is not shielded by the coil, a change in the state of the core can be detected quickly and with high sensitivity.

An insulating coating member that covers at least a surface of the core facing the coil may be further provided, and the sensor head may be disposed between the insulating coating member and the coil.
According to this configuration, reliable insulation between the core and the coil is ensured.

A sensor fixing part for fixing the sensor head may be formed on the insulating covering member.
According to this configuration, the sensor head can be easily attached to the coil device, and the sensor head can be attached at a predetermined position where the sensor fixing portion is formed.

The sensor head may have a substantially cylindrical shape, and the sensor fixing portion may have a fitting hole into which the cylindrical surface of the sensor head is fitted.
According to this configuration, no other attachment member (for example, a screw or a fixture) is required, and the sensor is fixed by simply inserting the sensor head into the insertion hole. Therefore, the sensor can be attached in a short work time. In addition, the sensor head can be accurately positioned in the radial direction of the insertion hole.

On the coil side of the insertion hole, a slit communicating with the external space may be formed over the entire axial length of the insertion hole.
According to this configuration, since the fitting force does not change greatly due to variations in the outer diameter of the sensor head, the sensor head can always be fixed with an appropriate fitting force.

The sensor fixing portion may further include a wall portion formed at the tip of the insertion hole and in contact with one of the end surfaces of the sensor head.
According to this configuration, the sensor head can be accurately positioned in the axial direction by abutting the end surface (for example, the base end) of the sensor head against the wall portion.

The sensor includes a lead extending from one end surface of the sensor head, and the core includes first and second linear core portions arranged in parallel and adjacent ends of the first and second linear core portions. A ring core having a pair of connecting core portions to be connected to each other, the first and second linear core portions and the pair of connecting core portions are covered with an insulating covering member, and the coil is a first and second linear core portion. And the sensor fixing part is formed on the inner surface facing the second linear core part in the part covering the first linear core part of the insulating coating member. In addition, a guide groove that accommodates the lead and guides it to the upper surface of the connecting core portion may be formed along the inner side surface of the insulating coating member that covers the connecting core portion.
According to this configuration, the sensor fixing portion can be provided without increasing the number of parts, and it is also possible to prevent the lead from interfering with the assembly of the reactor body. Moreover, since the temperature of the inner surface is relatively close to the temperature of the hot spot, when the sensor is a temperature sensor, it is possible to appropriately control the temperature of the hot spot using this sensor.

On the inner side surface, an upper side protruding portion that protrudes from the inner side surface and guides the lead from the sensor fixing portion to the guide groove by the lower surface thereof may be formed.
According to this configuration, it is possible to wire the leads along a desired path from the sensor fixing portion to the guide groove.

A lead fixing part for fixing the lead may be formed in the vicinity of the guide groove on the upper surface of the connecting core part.
According to this configuration, the sensor head is fixed in the sensor fixing portion by winding the lead guided to the upper surface of the connecting core portion by the upper protruding portion and the guide groove around the lead winding portion without slack. Further, when the coil is mounted on the core, the lead does not come into contact with the coil due to the slack of the lead, and the mounting of the coil is not hindered.

The sensor head has a substantially columnar shape, the sensor includes a lead extending from one end surface of the sensor head, and the sensor fixing portion is formed at a groove portion for accommodating the sensor head and at one end of the groove portion, and is in contact with one end surface of the sensor head. The wall portion may be configured such that a slit that is thinner than the sensor head and allows the lead to pass therethrough is formed in the wall portion.
According to this configuration, the sensor head is accommodated in the groove portion, the lead is pulled out from the slit, and the one end surface of the sensor head is brought into contact with the wall portion, so that an additional component for mounting the sensor head is not required. The head can be accurately arranged at a predetermined position.

At least the wall part side of the groove part is an extended part where the groove width widens toward the wall part, and one end of the slit is opened in a gap part formed in the wall part and wider than the cross section of the sensor head The other end of the slit may be closed.
According to this configuration, after the sensor head is introduced into the groove through a space wider than the cross section, the lead is inserted into the slit and then pulled to the opposite side of the groove, so that one end surface of the sensor head is brought into contact with the wall. Thus, the sensor head can be accurately arranged at a predetermined position. That is, the sensor head can be placed at a predetermined position by simply moving the sensor head within the gap between the core and the coil where the groove is formed (and the space in which the groove is extended in the longitudinal direction). The sensor head can be mounted even after the core is inserted.

The sensor fixing portion may be configured to further include a lead winding portion that is erected on the other end side of the slit and on which the lead is wound or hooked.
According to this configuration, after the sensor head is accommodated in the groove portion, the lead is pressed against the other end where the slit is closed by winding or hooking the lead around the lead winding portion, and the lead does not come out of the slit.

The lead winding part may be configured to have an upright part protruding from the surface of the core and an arm part extending from the tip of the upright part to the opposite side of the slit substantially parallel to the surface of the core.
According to this configuration, the lead is prevented from coming off from the tip of the upright portion by the arm portion extending to the opposite side to the slit of the upright portion on which the lead is hung.

The coil may be disposed along one surface, and further includes a base on which the core and the coil are fixed, and the lead winding portion may be configured to be erected on a surface opposite to the base of the core.
According to this configuration, the sensor can be easily attached to the coil device even after the coil device is assembled (after the core and the coil are attached on the base).

The gap may be a through hole or a recess that communicates with the slit formed in the wall.
According to this structure, a sensor head can be inserted in a groove part through a through-hole or a recessed part.

The sensor fixing part may be configured to further include a guide groove that is provided on the opposite side of the wall part from the groove part and communicates with the groove part through a through hole or a concave part.
According to this configuration, since the guide groove guides the sensor head to the through hole or the concave portion, it is easy to pass the sensor head through the through hole or the concave portion.

The coil has a linear coil part, the core has a linear core part arranged in the linear coil part, and the insulating coating member protrudes from the side surfaces of both ends of the linear core part, and the linear coil part extends from both sides in the axial direction. It may further include a flange portion to be sandwiched, and the wall portion may be formed as a part of the flange portion.
According to this configuration, after assembling the coil device, the sensor head can be disposed at a predetermined position between the core and the coil via a gap (through hole or recess) formed in the flange portion. Become.

The insulating coating member may be integrally formed with the core by insert molding.
According to this configuration, since the gap between the core and the insulating coating member (bobbin) can be minimized, the coil device can be downsized.

The insulating covering member may be a bobbin formed separately from the core.
According to this configuration, the present invention can be applied to a coil device having a conventional structure only by changing the shape of the bobbin without performing a significant design change or manufacturing equipment change.

The sensor may be a temperature sensor.
According to this configuration, more appropriate temperature management of the coil device is possible.

  The configuration of the embodiment of the present invention provides a sensor fixing structure having high responsiveness to both the core and coil states.

It is a perspective view of the reactor which concerns on 1st Embodiment of this invention. It is an exploded view of the reactor which concerns on 1st Embodiment of this invention. It is a perspective view of the U type core core unit concerning a 1st embodiment of the present invention. It is a front view of the U type core core unit concerning a 1st embodiment of the present invention. It is a top view of the U type core core unit concerning a 1st embodiment of the present invention. It is AA sectional drawing in FIG. It is a perspective view of the core module which concerns on 2nd Embodiment of this invention. It is a top view of the core module which concerns on 2nd Embodiment of this invention. It is a side view of the core module which concerns on 2nd Embodiment of this invention. It is a perspective view of the core module which concerns on the modification of 2nd Embodiment of this invention. It is a Y direction side view of the core module which concerns on the modification of 2nd Embodiment of this invention. It is a X direction side view of the core module which concerns on the modification of 2nd Embodiment of this invention. It is a Y direction side view of the core module which concerns on the modification of 3rd Embodiment of this invention.

  Hereinafter, the reactor 1 (FIGS. 1-6) which concerns on 1st Embodiment of this invention, the reactor 1000 (FIGS. 7-9) which concerns on 2nd Embodiment, and the reactor 2000 (FIG. 10 which concerns on the modification of 2nd Embodiment). 12) and the reactor 3000 (FIG. 13) according to the third embodiment will be described with reference to the drawings.

(First embodiment)
First, the first embodiment will be described. FIG. 1 is a perspective view of a reactor 1, and FIG. 2 is an exploded view thereof. In the following description of the first embodiment, the direction from the lower left side to the upper right side in FIG. 1 is the depth direction (X axis direction), the direction from the lower right side to the upper left side is the width direction (Y axis direction), The direction from the lower side to the upper side is defined as the height direction (Z-axis direction). In addition, when using the reactor 1, you may arrange | position the reactor 1 toward what direction.

  As shown in FIGS. 1 and 2, the reactor 1 includes a coil 10, a core module 20, a pair of core fixtures 30, a thermistor 40, a heat dissipation case 50, and a terminal block 60. The reactor body 1 a is configured by the coil 10 and the core module 20. A pair of brackets 21b for attaching the core fixture 30 are formed at both ends in the X-axis direction of the reactor main body 1a (specifically, the core module 20). A nut is embedded in the bracket 21b by insert molding. The core fixing tool 30 is attached to the core module 20 by screwing and tightening the two bolts 72 passed through the mounting holes of the core fixing tool 30 into the female threads of the nuts embedded in the pair of brackets 21b.

  The heat radiating case 50 is a substantially box-shaped member made of a light metal (for example, an aluminum alloy) with good thermal conductivity and accommodates the reactor body 1a. A mounting seat 52 having a female screw 52f for mounting the core fixing tool 30 is formed inside both ends of the heat radiating case 50 in the X-axis direction. The reactor main body 1a to which the core fixing tool 30 is attached is housed in the heat radiating case 50, and the core fixing tool 30 is fixed to the mounting seat 52 with bolts 74, whereby the reactor main body 1a is fixed in the heat radiating case 50. After the reactor main body 1a is mounted in the heat radiating case 50, a filler (not shown) is filled in the gap between the heat radiating case 50 and the reactor main body 1a. The heat radiating case 50 is installed on the cooling surface of the forced cooling device. That is, the bottom surface 50b of the heat radiating case 50 is in contact with the cooling surface of the forced cooling device, and most of the heat generated in the reactor 1 flows out to the cooling surface of the forced cooling device through the bottom surface 50b of the heat radiating case 50.

  A terminal block 60 is attached to one end of the edge of the heat radiating case 50 with a bolt 76. The terminal block 60 includes bus bars 62a and 62b, and the bus bars 62a and 62b are welded to the lead portions 13a and 13b of the coil 10, respectively.

  As shown in FIG. 2, the core module 20 has two U-shaped core units 20a and 20b formed in a substantially U-shape, but the U-shaped tips are abutted with each other via a gap member 20g and attached with an adhesive. Combined, it is a substantially O-shaped ring core. Each of the U-shaped core units 20a and 20b is obtained by coating a U-shaped core formed of a magnetic material with a resin by injection molding (insert molding). In addition, this resin coating is obtained by integrally forming an insulating bobbin that has been conventionally used to ensure electrical insulation between the core and the coil. The gap member 20g is a plate material of a non-magnetic material (for example, various ceramics such as alumina or resin) having a predetermined thickness. The U-shaped core unit 20a is formed with a sensor fixing portion 24 (FIGS. 3 to 6) for fixing the sensor head 42 of the thermistor 40. Details of the sensor fixing unit 24 will be described later.

  3, 4, and 5 are a perspective view, a front view, and a plan view of the U-shaped core unit 20 a on which the sensor fixing portion 24 is formed, respectively. FIG. 6 is a cross-sectional view taken along line AA in FIG. The U-shaped core unit 20a includes a pair of substantially rectangular parallelepiped linear core portions 22a and 22b arranged in parallel to each other and a substantially trapezoidal columnar shape (a rectangular columnar shape having a substantially trapezoidal bottom surface) that connects the linear core portions 22a and 22b. ) Of the connecting core portion 21. In the straight core portions 22a and 22b, substantially rectangular parallelepiped I-type core pieces 22c formed of a magnetic material are embedded. Further, the connecting core portion 21 is embedded with a substantially trapezoidal columnar connecting core piece 21c (FIG. 6) formed of a magnetic material. The two I-type core pieces 22c are each bonded and fixed to the connecting core piece 21c via a non-magnetic gap member (not shown), and formed into a substantially U-shaped U-shaped core. The U-shaped core unit 20a is obtained by coating the U-shaped core with a resin by injection molding (insert molding). Note that both end faces 22f of the U-shaped core unit 20a serving as a gap face are exposed without being covered. A heat resistant resin such as polyphenylene sulfide (PPS) is used for the coating resin of the U-shaped core unit 20a. Moreover, in this embodiment, although a powder magnetic core is used for each core piece 21c, 22c, you may use a silicon steel plate or a ferrite. The U-shaped core unit 20b has the same general configuration as the U-shaped core unit 20a, but the length of the linear core portions 22a and 22b (dimension in the X-axis direction) is short, and a structure for fixing the sensor is also provided. It differs from the U-shaped core unit 20a in that it is not formed. Note that the U-shaped core unit 20a and the U-shaped core unit 20b may have the same configuration.

  The coil 10 has a structure in which two linear coil portions 12a and 12b having the same structure formed of flat enamel wires are arranged in parallel and one ends (upper right ends in FIG. 2) are connected to each other. After passing the two linear core portions 22a and 22b of the U-shaped core unit 20a through the hollow portions of the two linear coil portions 12a and 12b, the end surfaces of the U-shaped core unit 20b and the end surfaces are brought into contact with each other via the gap member 20g. When bonded, the reactor body 1a is formed. As shown in FIG. 2, flange portions 20 f are respectively formed at the boundary portions between the straight core portions 22 a and 22 b and the connecting core portion 21 of the U-shaped core units 20 a and 20 b. The coil 10 is sandwiched between the flange portions 20f of the U-shaped core units 20a and 20b so as not to move in the X-axis direction.

Next, details of the sensor fixing part 24 formed in the U-shaped core unit 20a will be described. As shown in FIGS. 3 and 4, the sensor fixing portion 24 of the present embodiment is disposed below the surface (inner side surface 22s) of the linear core portion 22a that faces the inner peripheral surface of the linear coil portion 12a. It is formed from the resin coating of the part 22a. The sensor fixing portion 24 protrudes from the inner side surface 22s, and an insertion hole 241 extending in the coil axis direction (X-axis direction) is formed inside. The fitting hole 241 is formed in a substantially cylindrical shape having a slightly narrower diameter than the sensor head 42 so that the sensor head 42 of the thermistor 40 is fitted. A taper 242 is formed at the entrance (an opening adjacent to the gap surface 22f) of the insertion hole 241 so that the thermistor 40 can be easily inserted into the insertion hole 241. Further, the projecting portions 244 and 245 of the sensor fixing portion 24 have a predetermined height from the inner side surface 22s so that the sensor fixing portion 24 does not interfere with the linear coil portion 12a when the linear core portion 22a is inserted into the linear coil portion 12a. That is, it is cut off (in a plane parallel to the inner peripheral surface of the opposing linear coil portion 12a). Therefore, the insertion hole 241 is exposed to the outside, and a slit 243 communicating with the external space is formed in the cylindrical surface of the insertion hole 241 over the entire length in the coil axis direction. A portion where the sensor fixing portion 24 protrudes from the inner side surface 22 s is divided into an upper protruding portion 244 disposed above the slit 243 and a lower protruding portion 245 disposed below the slit 243. The upper protruding portion 244 is formed over substantially the entire length of the linear core portion 22a in the X-axis direction. On the other hand, the length (X-axis direction dimension) of the lower protrusion 245 is slightly longer than the entire length of the sensor head 42 of the thermistor 40. The insertion hole 241 is also formed to have the same length as the lower protrusion 245, and a wall 246 is formed at the tip of the insertion hole 241 (the right end in FIGS. 5 and 6). An opening 247 communicating with the external space is formed in the wall portion 246.

  The thermistor 40 attached to the reactor 1 of the present embodiment includes a substantially cylindrical sensor head 42 and a lead 44 extending from the base end of the sensor head 42. The thermistor element is disposed near the tip in the sensor head 42. When the thermistor 40 is attached, the sensor head 42 is inserted into the insertion hole 241 from the base end side. When the sensor head 42 is inserted to the innermost part of the insertion hole 241, the base end of the sensor head 42 comes into contact with the wall portion 246. Thereby, the sensor head 42 is positioned with respect to the core module 20 in the X-axis direction. Further, the sensor head 42 is positioned in the Y-axis and Z-axis directions with respect to the core module 20 by being inserted into the insertion hole 241. Therefore, the sensor head 42 is accurately positioned with respect to the core module 20 by inserting the sensor head 42 into the insertion hole 241 to the innermost part. Further, the lead 44 is passed through an opening 247 provided in the wall portion 246 and wired to the connecting core portion 21 along the lower surface of the upper protruding portion 244. The lower surface of the upper protrusion 244 is also a cylindrical surface having the same diameter as the insertion hole 241. Further, the opening 247 communicates with the slit 243, and the lead 44 is passed from the side surface of the sensor fixing portion 24 through the opening 247 through the slit 243.

  A guide groove 26 extending in the vertical direction (Z-axis direction) is formed in the resin coating portion of the connecting core portion 21 in the vicinity of the boundary with the inner side surface 22s of the linear core portion 22a. In addition, three lead winding pins 21 t for winding and fixing the leads are formed on the upper surface of the connecting core portion 21 in the vicinity of the guide groove 26. The lead winding pin 21t is also formed of a coating resin. The lead 44 guided to the connecting core portion 21 by the upper protruding portion 244 is guided to the upper surface of the connecting core portion 21 through the guide groove 26 and is entangled with the lead winding pin 21t so as not to be loosened. Not wired to the control unit. In this way, the lead 44 is reliably wired at a predetermined position by the upper protruding portion 244 and the guide groove 26, so that the lead 44 is prevented from becoming an obstacle to the assembly of the reactor 1. Further, since the guide groove 26 accommodates the lead 44, when the coil 10 is mounted on the U-shaped core unit 20a, the lead 44 does not prevent the coil 10 from approaching the connecting core portion 21, and the coil 10 is connected. The flange portion 20f of the core portion 21 is securely abutted and correctly positioned.

In the reactor having the structure as in the above embodiment, the bent portion at the center of the upper surface of the coil 10 becomes a hot spot H (FIG. 1) that reaches the maximum temperature in the reactor. The purpose of reactor temperature control is to maintain the temperature of the hot spot H below the upper limit value. However, in the actual product, it is difficult to accurately measure the temperature of the hot spot H. For this reason, a measured value having a high correlation with the temperature of the hot spot H is obtained, and a thermistor is arranged at a position where the mounting is easy. That is, in determining the thermistor arrangement and the fixed structure, the correlation between the measured value of the thermistor and the actual temperature of the hot spot H and the ease of attachment of the thermistor are important factors.
In the conventional configuration in which the sensor head is disposed in the gap between the linear coil portions 12a and 12b (that is, outside the coil), the actual temperature of the hot spot H reaches the peak when the thermistor detects the peak temperature during the operation of the reactor. It is delayed several seconds to several ten seconds from the timing.
On the other hand, in the reactor 1 of the above embodiment, the delay time of the timing at which the thermistor detects the peak temperature with respect to the timing at which the actual temperature of the hot spot H reaches the peak is less than the detection limit (0.1 seconds).
Even when the sensor head is arranged between the coil 10, the lower surface, the upper surface, and the outer surface of the core module 20, the delay time of the timing for detecting the peak temperature is similarly below the detection limit.
In other words, the configuration in which the sensor head is disposed between the core and the coil enables temperature measurement without time delay with respect to the temperature change of the hot spot H.

  Further, in the conventional configuration in which the sensor head is disposed outside the coil, the sensor head is shielded from the core by the coil, so that the temperature change of the core cannot be detected promptly. In the above embodiment, the sensor head is arranged between the core and the coil, which are the two main heat generating members, so that the temperature change of both the core and the coil can be detected with high sensitivity and promptly. Temperature management becomes possible.

  Further, in the above-described embodiment, the sensor head 42 is accurately positioned in all directions with respect to the sensor fixing portion 24 (that is, the core 20) by being inserted into the insertion hole 241 and contacting the wall portion 246. . As a result, measurement errors due to variations in the arrangement of sensor heads are reduced.

  In the above-described embodiment, the sensor fixing portion 24 is provided in the resin coating portion (bobbin portion) of the core module, so that a new member for attaching the sensor head of the thermistor becomes unnecessary, and is necessary for attaching the sensor head. Space is also reduced. In particular, the width dimension (Y-axis direction) of the reactor can be reduced as compared with the conventional configuration in which the sensor fixing structure is provided between the linear coil portions.

  In the above embodiment, since the slit 243 is formed in the insertion hole 241, the upper protrusion 244 and the lower protrusion 245 can be elastically deformed relatively freely, and the insertion hole 241 and the sensor head A moderate fitting force can be applied between the first and second members 42. With this configuration, a sensor fixing structure is realized in which the sensor head 42 is easily inserted into the insertion hole 241 and is not easily removed once inserted.

  In addition, the slit 243 of the sensor fixing portion 24 communicates with the opening 247 formed in the wall portion 246, so that the slit 243 can be formed from the side surface of the sensor fixing portion 24 without inserting the lead 44 of the thermistor 40 into the thin opening 247. Therefore, the thermistor can be attached without taking time and effort.

  In the above embodiment, the sensor head 42 of the thermistor 40 is disposed near the lower end of the inner side surface 22s of the linear core portion 22, but the sensor head is disposed at an arbitrary position as long as it is a gap between the core and the coil. Can do. For example, the sensor head may be disposed near the upper end of the inner side surface 22s. In this case, since the sensor head is disposed in the vicinity of the hot spot H (FIG. 1) that is the highest temperature in the reactor, a measured value close to the temperature of the hot spot can be obtained, and the operation of the reactor is more appropriately controlled. It becomes possible. Moreover, the width direction dimension of a reactor main body can be reduced similarly to said embodiment.

  The sensor head may be disposed on the upper side of the core (for example, the upper surface of the core module). Also in this case, since the sensor head is arranged near the hot spot H, more appropriate operation control of the reactor is possible. Moreover, the width direction (Y-axis direction) dimension of the reactor can be further reduced. Further, since the thermistor can be attached after the reactor is assembled, the reactor can be easily assembled and the thermistor can be easily attached.

  Further, the sensor head may be disposed on the lower side of the core (for example, the lower surface of the core module). Also in this case, the width direction dimension of the reactor can be significantly reduced.

(Second Embodiment)
Next, the reactor 1000 which concerns on 2nd Embodiment of this invention is demonstrated. In the following description of the second embodiment, the same or similar reference numerals are used for the same or corresponding components as those in the first embodiment, and duplicate descriptions are omitted. The configuration excluding the sensor fixing portion 1024 (sensor fixing portion 24) and the lead winding portion 1021t (lead winding pin 21t) provided in the core module 1020 of the reactor 1000 is the same as the reactor 1 of the first embodiment. The second embodiment will be described with a focus on differences from the first embodiment.

  FIG. 7 is a perspective view of the core module 1020 of the reactor 1000 to which the thermistor 40 is attached. In the following description of the second embodiment, the direction from the lower left side to the upper right side in FIG. 7 is the depth direction (X axis direction), the direction from the lower right side to the upper left side is the width direction (Y axis direction), The direction from the lower side to the upper side is defined as the height direction (Z-axis direction). 8 is a plan view of the core module 1020, and FIG. 9 is a side view of the core module 1020 as viewed in the negative X-axis direction.

  In the reactor 1000, a sensor fixing portion 1024 for fixing the sensor head 42 of the thermistor 40 is formed on the upper surface of the linear core portion 1022a of the U-shaped core unit 1020a that constitutes the core module 1020. The sensor fixing part 1024 has a groove part 1241 in which the sensor head 42 is accommodated. The groove part 1241 extends in the X-axis positive direction from the flange part 1020f. Further, the tip end portion (upper end portion in FIG. 8) of the groove portion 1241 in which the tip end portion of the sensor head 42 is accommodated is formed at substantially the center in the X-axis direction and the Y-axis direction of the linear core portion 1022a. The groove part 1241 penetrates the flange part 1020f and reaches the end (the lower end in FIG. 8) of the U-shaped core unit 1020a. A through hole 1244 is formed in the flange portion 1020f. In addition, a protruding portion 1243 protruding upward is formed in the vicinity of the groove portion 1241 of the flange portion 1020f.

  Further, the lead 44 of the thermistor 40 is wound (or hooked) on the Y axis positive direction side (right side in FIG. 8) adjacent to the X axis positive direction side (lower side in FIG. 8) of the flange portion 1020f. ) Is provided. The lead winding portion 1021t has an upright portion 1211 protruding from the upper surface of the connecting core portion 1021c and an arm portion 1212 extending from the upper end of the upright portion 1211 to the Y axis positive direction side. The arm portion 1212 extends downward at the tip, and the lead winding portion 1021t is formed in a substantially Γ shape when viewed from the X-axis direction.

  The front end side (the upper side in FIG. 8) of the groove portion 1241 is a constant width portion 1241a having a constant groove width slightly wider than the outer diameter of the sensor head 42. Further, the base end side (the lower side in FIG. 8) of the groove portion 1241 is a substantially V-shaped extension portion 1241b in which the groove width increases as it approaches the flange portion 1020f. Specifically, in the expanded portion 1241b, the other side of the groove portion 1241 is arranged such that the side wall on the Y axis negative direction side (left side in FIG. 8) of the groove portion 1241 is displaced toward the Y axis negative direction side as it approaches the flange portion 1020f. It is inclined with respect to the side wall (parallel to the ZX plane). Hereinafter, this inclined side wall is referred to as “inclined side wall 1241s”.

  The odd-shaped through hole 1244 formed in the flange portion 1020f has a large diameter portion 1244a formed on the inclined side wall 1241s side and a slit portion 1244b formed on the other side wall side of the groove portion 1241. The large diameter portion 1244a has a substantially round hole shape, and is formed to have a diameter slightly larger than the outer diameter of the sensor head 42. Further, the slit portion 1244b is formed elongated in the Y-axis direction. The dimension of the slit portion 1244 b in the short direction (Z-axis direction) is smaller than the outer diameter of the sensor head 42 and larger than the width of the lead 44. That is, the sensor head 42 and the lead 44 can pass through the large diameter portion 1244a, and the lead 44 can pass through the slit portion 1244b, but the sensor head 42 cannot pass through.

  When the sensor head 42 of the thermistor 40 is fixed to the sensor fixing portion 1024, the sensor head 42 is inserted into the groove portion 1241 from the large diameter portion 1244a of the through hole 1244 and the entire sensor head 42 is accommodated in the groove portion 1241. The lead 44 extending from the base end of the sensor head 42 is moved to the slit portion 1244b of the through hole 1244. Next, the lead 44 is wound around the lead winding portion 1021t while being pulled lightly so as not to loosen. At this time, the sensor head 42 is pulled by the lead 44 and approaches the through hole 1244, but cannot pass through the slit portion 1244b, and the base end of the sensor head 42 abuts against the flange portion 1020f and is fixed.

  The slit portion 1244b of the through hole 1244 is formed closer to the lead winding portion 1021t than the large diameter portion 1244a. Therefore, if the lead 44 is pulled and entangled with the lead winding portion 1021t, the lead 44 does not come off from the slit portion 1244b to the large diameter portion 1244a, and the sensor head 42 falls out of the groove portion 1241 through the large diameter portion 1244a. Is prevented. Further, the lead 44 is hooked to the side surface on the distal side (right side in FIG. 9) from the through hole 1244 in the upright portion 1211 of the lead winding portion 1021t. Since the arm portion 1212 of the lead winding portion 1021t is also formed on the distal side with respect to the through hole 1244, the arm portion 1212 prevents the lead 44 from slipping out of the side surface of the upright portion 1211. Further, a concave portion 1245 is formed on the lead winding portion 1021t side of the protruding portion 1243. As a result, a wide gap is secured between the upright portion 1211 and the protruding portion 1243, and the protruding portion 1243 is prevented from obstructing the winding of the lead 44. Further, as described above, the groove part 1241 penetrates the flange part 1020f and reaches the upper surface of the connecting core part 1021c to form the guide groove 1246. The groove part 1241 formed on the upper surface of the connecting core part 1021c functions as a guide when the sensor head 42 is passed through the through hole 1244, and makes the sensor head 42 easily passed through the through hole 1244.

(Modification of the second embodiment)
In the second embodiment, the groove portion 1241 of the sensor fixing portion 1024 in which the sensor head 42 is accommodated is formed on the upper surface of the linear core portion 1022, but the other surface of the core module 1020 (for example, the linear core portion 1022). The outer surface, the lower surface, the inner surface, etc.) may be provided with grooves. Next, a modification of the second embodiment of the present invention in which the groove portion of the sensor fixing portion is provided on the outer surface of the linear core portion will be described. In the following description of the modified examples, the same or similar reference numerals are used for the same or corresponding components as those in the second embodiment, and duplicate descriptions are omitted.

  FIG. 10 is a perspective view of a core module 2020 (a state where the thermistor 40 is attached) of a reactor 2000 according to a modification of the second embodiment of the present invention. In the following description, the direction from the lower left side to the upper right side in FIG. 10 is the depth direction (X axis direction), the direction from the lower right side to the upper left side is the width direction (Y axis direction), and the direction is from the lower side to the upper side. Is defined as the height direction (Z-axis direction). FIG. 11 is a side view seen in the positive direction of the Y axis, and FIG. 12 is a side view seen in the positive direction of the X axis.

  In the reactor 2000, a sensor fixing portion 2024 for fixing the sensor head 42 of the thermistor 40 is formed on the outer surface of the linear core portion 2022a of the U-shaped core unit 2020a that constitutes the core module 2020. The sensor fixing portion 2024 has a groove portion 2241 in which the sensor head 42 is accommodated. The groove portion 2241 extends in the positive X-axis direction from the flange portion 2020f. As shown in FIG. 11, the groove portion 2241 is formed in a substantially V shape in which the groove width increases toward the flange portion 2020f. That is, the entire groove portion 2241 is an extended portion. The groove width at the tip of the groove portion 2241 is slightly wider than the outer diameter of the sensor head 42. Further, the tip of the groove 2241 (the right end in FIG. 11) in which the tip of the sensor head 42 is accommodated is formed at the approximate center in the X-axis direction and the Z-axis direction of the linear core portion 2022a.

  The lower side wall 2241t of the groove portion 2241 is slightly inclined with respect to the XY plane (horizontal plane) so that the flange portion 2020f side (X-axis negative direction side) is higher. Further, the upper side wall 2241 s of the groove 2241 is further inclined in the same direction as the side wall 2241 t with respect to the XY plane. The groove portion 2241 passes through the flange portion 2020f, and a through hole 2244 is formed in the flange portion 2020f.

  The flange portion 2020f is formed with an odd-shaped through hole 2244 similar to the second embodiment described above. The through hole 2244 has a large diameter portion 2244a formed on the side wall 2241s side (lower side in FIG. 12) and a slit portion 2244b formed on the side wall 2241t side (upper side in FIG. 12) of the groove portion 2241. The large diameter portion 2244a has a substantially round hole shape, and is formed to have a diameter slightly larger than the outer diameter of the sensor head 42. Further, the slit portion 2244b is formed elongated in the Z-axis direction. The dimension of the slit portion 2244b in the short direction (X-axis direction) is smaller than the outer diameter of the sensor head 42 and larger than the width of the lead 44. That is, the sensor head 42 and the lead 44 can pass through the large diameter portion 2244a, and the lead 44 can pass through the slit portion 2244b, but the sensor head 42 cannot pass through.

  From the periphery of the through hole 2244 of the flange portion 2020f, a substantially U-shaped guide groove portion 2246 opened on the upper side protrudes in the negative X-axis direction. A wall portion 2246a on the side of the connecting core portion 2021c of the guide groove portion 2246 is integrated with the connecting core portion 1021c. A lead winding portion 2021t is provided at the upper end of the front end portion (left end portion in FIG. 11) of the wall portion 2246a. The lead winding part 2021t has an upright part 2211 protruding perpendicularly from the upper surface of the connecting core part 2021c, and an arm part 2212 extending from the upper end of the upright part 2211 to the Y axis positive direction side.

  When the sensor head 42 of the thermistor 40 is fixed to the sensor fixing portion 2024, the sensor head 42 is inserted into the groove portion 2241 from the large-diameter portion 2244a of the through hole 2244, and the entire sensor head 42 is accommodated in the groove portion 2241. When the lead 44 is hooked on the lead winding portion 2021t and then pulled, the lead 44 is pulled upward and moved to the slit portion 2244b of the through hole 2244. At this time, the sensor head 42 is pulled by the lead 44 and approaches the through hole 2244, but cannot pass through the slit portion 2244b, and the base end of the sensor head 42 abuts against the flange portion 2020f and is fixed.

  The slit portion 2244b of the through hole 2244 is formed closer to the lead winding portion 2021t than the large diameter portion 2244a. Therefore, if the lead 44 is hooked on the lead winding portion 2021t and then pulled to remove the slack, the lead 44 will not come off from the slit portion 2244b, and the sensor head 42 is prevented from falling out of the groove portion 2241 through the large diameter portion 2244a. . Further, the lead 44 is hooked on the side surface on the distal side (the left side in FIG. 11) with respect to the through hole 2244 in the upright portion 2211 of the lead winding portion 2021t. Since the arm portion 2212 of the lead winding portion 2021t is also formed on the distal side with respect to the through hole 2244, the arm portion 2212 effectively prevents the lead 44 from sliding off the side surface of the upright portion 2211. The substantially U-shaped guide groove 2246 functions as a guide when the sensor head 42 is inserted into the through hole 2244, and makes it easy to pass the sensor head 42 through the through hole 2244.

  In the above-described second embodiment and its modification, the through holes 1244 and 2244 are holes closed from the outside, but these may be formed as recesses (grooves) opened to the outside.

  In the second embodiment described above and its modification, the groove portions 1241 and 2241 of the sensor fixing portions 1024 and 2024 are formed adjacent to the flange portions 1020f and 2020f, and the sensor head 42 and the lead 44 are formed in the flange portions 1020f and 2020f. Although through holes 1244 and 2244 are formed to pass through, the groove portion of the sensor fixing portion may be provided on the surface where the flange portion is not formed. In that case, a through hole (a large diameter part and a slit part) is formed at one end of the extended part side of the groove part, and a wall part is provided.

(Third embodiment)
Next, a third embodiment of the present invention will be described. In the third embodiment as well, as in the modification of the second embodiment described above, the groove portion of the sensor fixing portion is provided on the outer surface of the linear core portion of the core module. However, the shape of the groove and the configuration for accommodating the thermistor in the groove are different from the above embodiments. FIG. 13: is the side view which looked at the core module 3020 of the reactor 3000 which concerns on 3rd Embodiment of this invention in the Y-axis positive direction. Reactor 3000 differs from reactor 2000 according to the modification of the second embodiment only in the configuration of the core module and the thermistor arrangement. In the following description of the third embodiment, the same or similar reference numerals are used for the same or corresponding components as those of the above-described embodiments, and duplicate descriptions are omitted. In addition, the same coordinates as those in the above embodiments are used.

  Similar to the modified example of the second embodiment, the sensor fixing portion 3024 of the core module 3020 also extends along the through hole 3244 formed in the flange portion 3020f and the outer surface of the straight core portion 3022 of the core module 3020 from the through hole 3244. And a guide groove 3246 extending from the through hole 3244 to the opposite side of the groove 3241, and a lead winding part 3021t. The groove portion 3241 has an introduction portion 3241a formed to be inclined slightly downward (Z-axis negative direction) from the through hole 3244 toward the center portion of the outer surface of the linear core portion 3022, and slightly above the tip of the introduction portion 3241a (Z It has a holding portion 3241b formed to be inclined in the positive axial direction. The introduction part 3241a and the holding part 3241b have two side walls (lower side walls 3241a1 and 3241b1 and upper side walls 3241a2 and 3241b2) that are substantially parallel to each other. In addition, the lower side wall 3241b1 and the upper side wall 3241b2 of the holding portion 3241b are connected by a side wall 3241b3 formed in a substantially U shape. The lower side wall 3241a1 of the introduction part 3241a and the lower side wall 3241b1 of the holding part 3241b are connected via a step part 3241c.

  In the third embodiment, the method of inserting and fixing the sensor head 42 of the thermistor 40 into the groove is different from the modification of the second embodiment. In the modification of the second embodiment, the sensor head 42 of the thermistor 40 is inserted into the groove portion 2241 from the tip, and after the entire sensor head 42 is accommodated in the groove portion 2241, the lead 44 extending from the base end of the sensor head 42 is provided. The sensor head 42 is positioned and fixed by pulling the base end against the flange portion 2020f. On the other hand, in the third embodiment, the sensor head 42 is inserted into the groove portion 3241 from the base end side in a state where the lead 44 is folded back in a U-shape immediately after coming out of the base end of the sensor head 42, and The lead 44 is pulled after the whole reaches the holding portion 3241b, and the tip of the sensor head 42 is abutted against the stepped portion 3241c, whereby the sensor head 42 is positioned and fixed.

  Thus, in 3rd Embodiment, since the structure which fixes the sensor head 42 by abutting against the flange part 3020f like 2nd Embodiment and its modification is not employ | adopted, the through-hole 3244 is 2nd implementation. It is not a deformed hole such as the through-hole 2244 in the form, but is formed as a simple long hole (for example, a long round hole or a long angle hole) having a size through which the sensor head 42 and the folded lead 44 can pass.

  In the third embodiment, a lead winding portion 3021t is provided at the upper end of the wall portion 3246b of the guide groove portion 3246 on the Y axis negative direction side (the front side in FIG. 13). However, the lead winding part 3021t may be provided on the wall part on the connecting core part 2021c side or the upper surface of the connecting core part 2021c, as in the modification of the second embodiment.

  In the third embodiment, the straight portions of the two U-shaped core units 3020a and 3020b are formed to have substantially the same length, and the groove portion 3241 is formed across the two U-shaped core units 3020a and 3020b. . However, as in the second embodiment, the straight portion of the U-shaped core unit 3020a may be longer than the U-shaped core unit 3020b, and the groove 3241 may be formed only in the U-shaped core unit 3020a. Similarly, in the first and second embodiments, as in the third embodiment, a groove may be formed across two U-shaped core units 3020a and 3020b.

  The above is a description of three exemplary embodiments of the invention. Embodiments of the present invention are not limited to those described above, and can be arbitrarily changed within the scope of the technical idea expressed by the description of the scope of claims.

  For example, in each of the above embodiments, the coil device main body (for example, the reactor main body 1a) is accommodated in the heat dissipation case, but the heat dissipation case is not necessarily required. Moreover, you may fix a coil apparatus main body on a mere plate-shaped base instead of a thermal radiation case. In addition, the case or base to which the coil device main body is attached does not necessarily have to have a heat dissipation function formed from a metal having excellent thermal conductivity.

  In each of the above embodiments, the sensor head is fixed only by the structure provided on the resin coating portion (bobbin portion) of the core module. However, the sensor head may be attached to the core module with an adhesive or a fixture.

  Each of the above embodiments is an example in which the present invention is applied to a coil device using a core module in which a magnetic core and a bobbin (resin coating portion) are integrally formed by injection molding. The present invention can also be applied to a configuration in which the formed insulating bobbin made of resin is used. In this case, a sensor fixing portion may be provided on the bobbin.

  In addition, each of the above embodiments is an example in which the present invention is applied to the attachment of the thermistor to the coil device, but of course, the present invention is also applicable to the attachment of other types of temperature sensors (thermocouple, platinum temperature sensor, etc.). Can be applied. The present invention can also be applied to attachment of various sensors other than the temperature sensor (for example, a humidity sensor, a gas sensor, a vibration sensor, a magnetic sensor, a potential sensor, a sound pressure sensor, etc.).

  Each of the above embodiments is a reactor having a configuration in which each linear part of a ring core having two linear parts parallel to each other is wound by a linear coil connected in series, but the present invention is applied. The configuration of the coil device is not limited to this. For example, the present invention can also be applied to a three-phase reactor including a “day” -shaped core composed of an E-type core and an I-type core and three straight cores. Further, the present invention can be applied not only to a reactor but also to a transformer and other coil devices.

1, 1000, 2000, 3000 Reactor 10 Coil 20, 1020, 2020, 3020 Core module 20a, 20b, 1020a, 2020a, 3020a, 3020b U-type core unit 24, 1024, 2024, 3024 Sensor fixing part 40 Thermistor H Hot spot

Claims (15)

A coil device comprising a coil and a core at least partially passed through the coil,
A sensor for detecting a predetermined physical quantity in the coil device;
An insulating covering member covering at least a surface of the core facing the coil;
Further comprising
A sensor head of the sensor is disposed between the insulating coating member and the coil;
A sensor fixing part for fixing the sensor head is formed on the insulating coating member,
The sensor head is substantially cylindrical,
In the sensor fixing part,
A protrusion protruding from a surface facing the coil;
A substantially cylindrical insertion hole into which the cylindrical surface of the sensor head is inserted; and
A shape in which the protruding portion is cut out by a plane parallel to the inner peripheral surface of the coil,
Due to the shape, a slit that communicates with the external space is formed on the coil side of the insertion hole over the entire axial length of the insertion hole.
The coil apparatus characterized by the above-mentioned.   2. The coil device according to claim 1, wherein the sensor fixing portion further includes a wall portion formed at a tip end of the insertion hole and in contact with one end surface of the sensor head. The sensor includes a lead extending from the one end surface of the sensor head,
The core includes a first and second straight core portions arranged in parallel, and a pair of connecting core portions that respectively connect adjacent end portions of the first and second straight core portions. And the first and second straight core portions and the pair of connecting core portions are covered with the insulating covering member,
The coil includes first and second linear coils through which the first and second linear core portions are respectively passed.
The sensor fixing portion is formed on an inner surface facing the second linear core portion in a portion covering the first linear core portion of the insulating coating member,
A guide groove that accommodates the lead and guides to the upper surface of the connecting core portion is formed along the inner side surface in a portion of the insulating coating member that covers the connecting core portion. The coil apparatus as described in any one of Claim 1 or Claim 2.   4. The coil according to claim 3, wherein the inner side surface is formed with an upper side protruding portion that protrudes from the inner side surface and guides the lead from the sensor fixing portion to the guide groove by the lower surface thereof. apparatus.   5. The coil device according to claim 3, wherein a lead fixing portion for fixing the lead is formed in the vicinity of the guide groove on the upper surface of the connecting core portion. A coil device comprising a coil and a core at least partially passed through the coil,
A sensor for detecting a predetermined physical quantity in the coil device;
An insulating covering member covering at least a surface of the core facing the coil;
Further comprising
A sensor head of the sensor is disposed between the coil and the insulating covering member;
A sensor fixing part for fixing the sensor head is formed on the insulating coating member,
The sensor head is substantially columnar,
The sensor includes a lead extending from one end surface of the sensor head,
The sensor fixing part is
A groove for accommodating the sensor head;
A wall portion formed at one end of the groove portion and in contact with one end surface of the sensor head;
Have
The wall is formed with a slit that is thinner than the sensor head and through which the lead passes.
At least the wall portion side of the groove portion is an extended portion in which the groove width widens toward the wall portion,
One end of the slit is opened in a gap formed in the wall, wider than the cross section of the sensor head, and the other end of the slit is closed,
The coil apparatus characterized by the above-mentioned.   The coil device according to claim 6, wherein the sensor fixing portion further includes a lead winding portion that is erected on the other end side of the slit and on which the lead is wound or hooked.   The lead winding part includes an upright part protruding from the surface of the core, and an arm part extending from the upper end of the upright part to the opposite side of the slit substantially parallel to the surface of the core. The coil device according to claim 7. The coil is further disposed along one surface, and further includes a base on which the core and the coil are fixed.
9. The coil device according to claim 7, wherein the lead winding portion is erected on a surface of the core opposite to the base.   The coil device according to any one of claims 6 to 9, wherein the gap is a through hole or a recess that communicates with the slit formed in the wall.   The said sensor fixing | fixed part is further provided with the guide groove provided in the opposite side to the said groove part with respect to the said wall part, and communicating with the said groove part through the said through-hole or the said recessed part. The coil device according to 10. The coil has a linear coil portion;
The core has a linear core portion disposed in the linear coil portion;
The insulating covering member further has a flange portion that protrudes from side surfaces of both end portions of the linear core portion and sandwiches the linear coil portion from both sides in the axial direction.
The coil device according to any one of claims 10 to 11, wherein the wall portion is formed as a part of the flange portion.   The coil device according to any one of claims 1 to 12, wherein the insulating coating member is formed integrally with the core by insert molding.   The coil device according to any one of claims 1 to 12, wherein the insulating coating member is a bobbin formed separately from the core.   The coil device according to any one of claims 1 to 14, wherein the sensor is a temperature sensor.

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